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Dave's RV-7A Builder's Log
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Date:  9-18-2016
Number of Hours:  3.50
Manual Reference:  
Brief Description:  Fuel system and brake line plumbing

Today was the day to get the fuel system fully plumbed. Aluminum tubing in my shop quickly becomes an endangered species when I break out the tubing cutter and bender. I'm not sure why it is so hard for me to work out the bend angles and cut lengths without doing some trial and error, but I just can't seem to do the math in my head. After a few failed attempts, I finally figured out that a 2" drop, 45 degree bend, followed by an immediate 90 degree right turn and 1 1/2" run forward to the filter was the correct solution. Simple. With that, the fuel system was plumbed.


Next I decided to use what was left of my 1/4" 3003 to finish up the brake lines. I'm sure they make 1/4" 5052, but I'm sticking with the more flexible tubing to run some of the complex curves necessary to navigate the turns required for the fuel vent lines, brake lines, pitot lines, etc. I've ruined enough tubing...and I really don't think it's worth the time, money, and frustration to try and use 5052 for any of those.


The biggest challenge I faced was coaxing all of the tubing through the various brackets and cutting/flaring while laying on my side in the forward fuselage, but in the end, it was done. The plumbing is finished. There is a lot of tidying and "prettying up" left to do in the tunnel, but I really think I'm almost done with everything that runs from the spar to the firewall. Next session will include dropping the avionics rack to shoot the last six top skin rivets, reinstalling the fuel vent lines and rudder pedals, and then attaching the rudder cables. Progress!
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Fuel system is plumbed!

Fuel system is plumbed!

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View aft of the fuel selector

View aft of the fuel selector

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Pump-to-firewall run with brake lines installed

Pump-to-firewall run with brake lines installed

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